US20160106011A1 - Electric power converter - Google Patents
Electric power converter Download PDFInfo
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- US20160106011A1 US20160106011A1 US14/883,034 US201514883034A US2016106011A1 US 20160106011 A1 US20160106011 A1 US 20160106011A1 US 201514883034 A US201514883034 A US 201514883034A US 2016106011 A1 US2016106011 A1 US 2016106011A1
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- capacitor
- partition wall
- wall portion
- laminated body
- wall portions
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/2089—Modifications to facilitate cooling, ventilating, or heating for power electronics, e.g. for inverters for controlling motor
- H05K7/20927—Liquid coolant without phase change
Definitions
- the present disclosure relates to an electric power converter that has a semiconductor module with a built-in semiconductor element and a capacitor connected to the semiconductor module.
- a pressing member such as a leaf spring is housed in the metal casing.
- the laminated body is pressurized in a laminating direction by the pressing member.
- the laminated body is fixed in the metal casing.
- a capacitor connected to the semiconductor modules is housed in the metal casing.
- the metal casing includes outer wall portions that form an outer shell, and partition wall portions formed in the case, which are connected to the outer wall portions.
- a space within the metal casing is partitioned into a capacitor housing space for housing the capacitor and a laminated body housing space for housing the laminated to body by the partition walls.
- the pressing force of the pressing member is applied to the partition walls.
- the capacitor includes a capacitor case made of resin, capacitor elements disposed in the capacitor case, and a sealing member for sealing the capacitor elements in the capacitor case.
- the capacitor is housed in the capacitor housing space.
- a gap is formed between the capacitor case and the metal casing (refer to FIG. 10 ).
- the above-mentioned electric power converter has a problem that cooling performance of the capacitor is not sufficiently high. That is, as described above, in the above-mentioned electric power converter, the capacitor elements are sealed in the capacitor case, and the gap is formed between the capacitor case and the metal casing. Thereby, the heat generated from the capacitor elements is transmitted to the metal casing via the sealing member, the capacitor case, and the gap. Therefore, a thermal resistance from the capacitor elements to the metal casing is large, and it is impossible to increase sufficiently the cooling performance of the capacitor.
- An embodiment provides an electric power converter that can be downsized and lightened, while capable of improving cooling efficiency of a capacitor.
- an electric power converter includes a laminated body formed by laminating a plurality of semiconductor modules having built-in semiconductor elements and a plurality of cooling pipes for cooling the semiconductor modules alternately, a capacitor connected to the plurality of semiconductor modules, a pressing member that presses the laminated body in a laminating direction of the laminated body, and a metal case that houses the laminated body, the capacitor, and the pressing member.
- the case has outer wall portions that form an outer shell, and partition wall portions formed in the case that are connected to the outer wall portions, a space within the case being partitioned by the partition wall portions into a capacitor housing space for housing the capacitor and a laminated body housing space for housing the laminated body, the capacitor including capacitor elements housed in the capacitor housing space, and a sealing member that is filled in the capacitor housing space for sealing the capacitor elements, the capacitor being disposed at a position adjacent to the laminated body in the laminating direction, pressing force of the pressing member being applied to an interposing partition wall portion interposing between the laminated body and the capacitor among the partition well portions in its thickness direction, and a thickness of the interposing partition wall to portion is made thinner than any other parts of the outer wall portions.
- the capacitor housing space is filled with the sealing member.
- the sealing member can be brought into contact with the partition wall portions and the outer wall portions of the case. Therefore, the heat generated from the capacitor can be transmitted immediately to the metal case via the sealing member. As a result, it is possible to reduce the thermal resistance from the capacitor elements to the case, thus it is possible to enhance the cooling efficiency of the capacitor.
- the interposing partition wall portion interposed between the capacitor and the laminated body among the partition wall portions is formed thinner than any other parts of the outer wall portions. Therefore, it is possible to downsize and lighten the case.
- the capacitor housing space is filled with the sealing member, it is possible to bring the sealing member to contact with the interposing partition wall portion.
- there is no gap present between the sealing member and the interposing partition wall portion and even when the pressing force of the pressing member is applied to the interposing partition wall portion, the pressing force can be received by the sealing member. Therefore, it is possible to make the interposing partition wall portion thin, and it is possible to achieve downsizing and lightening of the case.
- the electric power converter that can further be lightened and downsized, and capable of improving the cooling efficiency of the capacitor.
- FIG. 1 shows a sectional view of an electric power converter, and is a sectional view taken along the line I-I of FIG. 2 in a first embodiment
- FIG. 2 shows a sectional view taken along the line II-II of FIG. 1 ;
- FIG. 3 shows a sectional view taken along the line of FIG. 1 ;
- FIG. 4 shows a sectional view taken along the line IV-IV of FIG. 2 ;
- FIG. 5 shows an exploded perspective view of a case main body in the first embodiment
- FIG. 6 shows a circuit diagram of the electric power converter in the first embodiment
- FIG. 7 shows a sectional view of an electric power converter in a second embodiment
- FIG. 8 shows a sectional view of an electric power converter in a third embodiment
- FIG. 9 shows a sectional view of an electric power converter in a fourth embodiment.
- FIG. 10 shows a sectional view of an electric power converter in a comparative example.
- An above-mentioned electric power converter can be defined as an on-vehicle electric power converter for mounting on a vehicle such as an electric vehicle or a hybrid vehicle.
- an electric power converter 1 of the present embodiment includes a laminated body 10 , a capacitor 3 , a metal case 4 , and a pressing member 5 .
- the laminated body 10 is formed by laminating a plurality of semiconductor modules 2 having built-in semiconductor elements 20 (refer to FIG. 6 ) and a plurality of cooling pipes 11 for cooling the semiconductor modules 2 alternately.
- the capacitor 3 is connected to the semiconductor modules 2 .
- the pressing member 5 presses the laminated body 10 in a laminating direction of the laminated body 10 (X-direction). Thereby, while ensuring a contact pressure between the semiconductor modules 2 and the cooling pipes 11 , the laminated body 10 is fixed in the case 4 .
- the above-mentioned laminated body 10 , the capacitor 3 , so and the pressing member 5 are housed in the case 4 .
- the case 4 has outer wall portions 41 that form an outer shell, and partition wall portions 42 formed in the case 4 and are connected to the outer wall portions 41 .
- a space within the case 4 is partitioned by the partition wall portions 42 into a capacitor housing space S C for housing the capacitor 3 and a laminated body housing space S L for housing the laminated body.
- the capacitor 3 includes capacitor elements 30 housed in the capacitor housing space S C , and a sealing member 31 that is filled in the capacitor housing space S C for sealing the capacitor elements 30 .
- the capacitor 3 is disposed at a position adjacent to the laminated body 10 in the X direction. Pressing force of the pressing member 5 is applied to an interposing partition wall portion 42 a interposing between the laminated body 10 and the capacitor 3 among the partition wall portions 42 in its thickness direction (X direction).
- the thickness of the interposing partition wall portion 42 a is made thinner than any other parts of the outer wall portions 41 .
- the electric power converter 1 of the present embodiment is an on-vehicle electric power converter for mounting on a vehicle such as an electric vehicle or a hybrid vehicle.
- an inverter circuit 200 is constituted by a plurality of semiconductor modules 2 in the present embodiment.
- DC power supplied from a DC power supply 81 is converted into AC power by turning on and off the semiconductor elements 20 (IGBT elements) in the semiconductor modules 2 .
- a three-phase AC motor 82 is driven by using the obtained AC power, thereby drives the vehicle.
- the capacitor 3 is connected to the semiconductor modules 2 .
- DC voltage applied to the semiconductor modifies 2 is smoothened by using the capacitor 3 .
- the electric power converter 1 of the present embodiment includes the interposing partition wall portion 42 a, a bottom partition wall portion 42 b, and a lateral partition wall portion 42 c as the partition wall portions 42 .
- the bottom partition wall portion 42 b is orthogonal to the interposing partition wall portion 42 a.
- the bottom partition wall portion 42 b is disposed on a side opposite to an opening 12 of the capacitor housing space S C .
- the lateral partition wall portion 42 c is orthogonal to both the interposing partition wall portion 42 a and the bottom partition wall portion 42 b.
- a space surrounded by the interposing partition wall portion 42 a, the bottom partition wall portion 42 b, the lateral partition wall portion 42 c, and the outer wall portions 41 is defined as the capacitor housing space S C .
- the thicknesses of the interposing partition wall portion 42 a, the bottom partition wall portion 42 b, and the lateral partition wall portion 42 c are made thinner than any other parts of the outer wall portions 41 .
- the space in the case 4 is divided into the capacitor housing space S C and the laminated body housing space S L by the partition wall portions 42 ( 42 a ⁇ 42 c ).
- a control circuit board 6 and a terminal block 16 are housed in the laminated body housing space SL.
- the capacitor 3 includes the capacitor elements 30 housed in the capacitor housing space SC, the sealing member 31 for sealing the capacitor elements 30 in the capacitor housing space SC, and electrode plates 32 , 33 connected to the capacitor elements 30 .
- the capacitor elements 30 are so-called film capacitors.
- the sealing member 31 is made of a thermosetting resin such as epoxy resin.
- the sealing member 31 fills gaps between the capacitor elements 30 , the electrode plates 32 , 33 , and the case 4 in the capacitor housing space S C . Thereby, the capacitor elements 30 and the electrode plates 32 , 33 are sealed.
- the electrode plates 32 , 33 are connected to electrode surfaces 350 , 351 of the capacitor elements 30 . Parts of the electrode plates 32 , 33 protrude from the sealing member 31 .
- the electrode plates 32 , 33 are integrated with DC bus bars 34 p, 34 n which will be described later.
- the capacitor elements 30 are housed into the capacitor housing space SC, then uncured sealing member 31 is injected. Then, heat is applied to cure the sealing member 31 . Thereby, the capacitor 3 is manufactured.
- the pressing member 5 is disposed in the X direction between the laminated body 10 and the interposing partition wall portion 42 a in the present embodiment.
- the pressing member 5 of the present embodiment is a leaf spring.
- the laminated body 10 is pressed toward the outer wall portion 41 a of the case 4 by the pressing member 5 .
- the pressing force F of the pressing member 5 is applied to the interposing partition wall portion 42 a and the capacitor 3 .
- Two cooling pipes 11 adjacent in the X direction are connected by connecting pipes 17 at both end portions thereof in a longitudinal direction of the cooling pipe 11 (Y-direction). Furthermore, an inlet pipe 13 for introducing a refrigerant 15 and an outlet pipe 14 for discharging the refrigerant 15 are connected to an end cooling pipe 11 a positioned at one end in the X direction among the plurality of cooling pipes 11 .
- the refrigerant 15 flows all of the cooling pipes 11 through the connecting pipes 17 , and discharged from the outlet pipe 14 . Thereby, the semiconductor modules 2 are cooled.
- the respective semiconductor module 2 has a main body 21 with a built-in semiconductor element 20 , and power terminals 22 and control terminals 23 protruding from the main body 21 .
- the power terminals 22 there are DC terminals 22 p, 22 n to which DC voltage is applied, and there are AC terminals 22 c connected to the three-phase AC motor 82 (refer to FIG. 6 ).
- the DC terminals 22 p, 22 n are connected to the capacitor 3 via the DC bus bars 34 p, 34 n.
- the control terminals 23 are connected to the control circuit board 6 .
- An on-off operation of the semiconductor element 20 (refer to FIG. 6 ) is controlled by the Control circuit board 6 .
- the DC power supplied from the DC power supply 81 is converted into the AC power,
- the electric power converter 1 includes input terminals 71 for being connected to the DC power supply 81 (refer to FIG. 6 ), and output terminals 72 for being connected to the three-phase AC motor 82 .
- the input terminals 71 are connected to the capacitor 3 .
- AC bus bars 720 are connected to the AC terminal 22 c of the semiconductor modules 2 . Ends of the AC bus bars 720 are the aforementioned output terminals 72 .
- the terminal block 16 for mounting the input terminals 71 and output terminals 72 are housed in the case 4 .
- the terminal block 16 is made of resin,
- the terminal block 16 is disposed at a position adjacent to the capacitor 3 in the Y direction,
- a connector insertion hole 49 is formed in the outer wall portion 41 of the case 4 .
- the connector insertion hole 49 penetrates in the Y direction.
- a connector 18 is inserted into the connector insertion hole 49 .
- Input connector terminals 181 of the connector 18 are connected to the input terminals 71 of the electric power converter 1 .
- output connector terminals 182 of the connector 18 are connected to the output terminals 72 .
- the electric power converter 1 is electrically connected to the DC power supply 81 and the three-phase AC motor 82 via the connector 18 .
- the case 4 of the present embodiment includes a case main body 401 for housing the laminated body 10 and the capacitor 3 , and covers 402 , 403 attached to the case main body 401 .
- the covers 402 , 403 also constitute the outer wall portions 41 of the case 4 .
- a plurality of reinforcing wall portions 43 are formed to the case main body 401 in addition to the partition wall portions 42 .
- a rigidity of the case 4 has been increased by the reinforcing wall portions 43 .
- the case 4 is configured not to be deformed by the pressing force F of the pressing member 5 (see FIG. 4 ).
- the outer wall portion 41 a to which the inlet pipe 13 and so the outlet pipe 14 are disposed has a double structure in which a first outer wall portion 411 and a second outer wall portion 412 are overlapped with each other.
- the first outer wall portion 411 is positioned on an inside of the case 4
- the second outer wall portion 412 is positioned on an outside of the case 4 .
- a through hole 44 penetrating in the X direction is formed in the first outer wall portion 411 .
- the through hole 44 is closed by the second outer wall portion 412 .
- the second outer wall portions 412 is fixed to the first outer wall portion 411 by bolts 48 .
- a distance L in the Y direction between the two reinforcing wall portions 43 a, 43 b adjacent in the Y direction is shorter than the length of the cooling pipe 11 in the Y-direction. Therefore, when manufacturing the electric power converter 1 , it is not possible to put the cooling pipes 11 in the case 4 through a gap G formed between the two reinforcing wall portions 43 a, 43 b. Therefore, the cooling pipes 11 are configured to be placed in the case 4 from the through hole 44 in the present embodiment.
- the capacitor housing space S C is filled with the sealing member 31 in the present embodiment.
- the sealing member 31 can be brought into contact with the partition wall portions 42 and the outer wall portions 41 of the case 4 . Therefore, heat generated from the capacitor elements 30 s can be transmitted immediately to the metal case 4 via the sealing member 31 . As a result, it is possible to reduce the thermal resistance from the capacitor elements 30 to the case 4 , and thus it is possible to enhance the cooling efficiency of the capacitor 3 .
- the interposing partition wall portion 42 a interposing between the capacitor 3 and the laminated body 10 is made thinner than any other parts of the outer wall portions 41 in the present embodiment. Therefore, it is possible to downsize the case 4 , and it can be lightened. Since the capacitor housing space S C is filled with the sealing member 31 in the present embodiment, it is possible to bring the sealing member 31 to contact with the interposing partition wall portion 42 a. Thus, there is no gap present between the sealing member 31 and the interposing partition wall portion 42 a, and even when the pressing force F of the pressing member 5 is applied to the interposing partition wall portion 42 a, the pressing force F can be received by the sealing member 31 . Therefore, it is possible to make the interposing partition wall portion 42 a thin, and it is possible to achieve downsizing and lightening of the case 4 .
- a capacitor 93 is constituted by sealing capacitor elements 930 in a capacitor case 99
- a gap g is formed between the capacitor 93 and a case 94 as a result. Therefore, heat generated from the capacitor elements 930 will be transmitted to the case 94 via a sealing member 931 , the capacitor case 99 , and the gap g.
- the thermal resistance from the capacitor elements 930 to the case 94 becomes large, and it becomes difficult to sufficiently enhance the cooling efficiency of the capacitor 93 .
- the pressing force F of a pressing member 95 is needed to be received by an interposing partition wall 942 a. Therefore, in order not to be deformed by the pressing force F, the interposing partition wall portion 942 a is needed to be formed thicker. Thus, the case 94 becomes large, and it tends to become heavy.
- the sealing member 31 comes into contact with the partition well portions 42 and the like of the case 4 by filling the capacitor housing space S C with the sealing member 31 as in the present embodiment, the heat generated from the capacitor elements 30 is transmitted immediately to the case 4 via the sealing member 31 . Therefore, it is possible to enhance the cooling efficiency of the capacitor 3 . Further, since no gap is formed between the sealing member 31 and the interposing partition wall portion 42 a , the pressing force F of the pressing member 5 applied to the interposing partition wall portion 42 a can be received by the sealing member 31 . Therefore, It is possible, to make the interposing partition wall portion 42 a thinner, thus the case 4 can be downsized and lightened.
- the bottom partition wall portion 42 b and the lateral partition wall portion 42 c are also made thinner than any other parts of the outer wall portions 41 in the present embodiment. Therefore, the case 4 can be more lightened, and can be more downsized. As a result, the electric power converter 1 can be lightened and downsized.
- a supporting outer wall portion 41 d disposed in a position farther from the laminated body 10 than the capacitor 3 is in the X direction is provided as the outer wall portion 41 in the present embodiment.
- the sealing member 31 , of the capacitor 3 is in contact with the supporting outer wall portion 41 d. Therefore, the pressing force F of the pressing member 5 applied to the sealing member 31 can be received by the supporting outer wall portions 41 d which is thicker than the partition wall portions 42 .
- the pressing member S is disposed between the laminated body 10 and the interposing partition wall portion 42 a in the present embodiment, the present disclosure is not limited thereto. That is, the pressing member 5 can also be disposed between the laminated body 10 and the outer wall portion 41 a. In this case, the pressing member 5 is to press the laminated body 10 toward the interposing partition wall portion 42 a.
- the present embodiment is an example that a shape of the case 4 is changed.
- the interposing partition wall portion 42 a is formed so as to connect two pieces of the outer wall portions 41 b, 41 c, in the present embodiment.
- the lateral partition wall portion 42 c (refer to FIG. 1 ) is not formed in the present embodiment.
- the bottom partition wall portion 42 b (refer to FIG. 3 ) is formed in the same manner as in the first embodiment in the present embodiment.
- a space surrounded by the interposing partition wall portion 42 a , the bottom partition wall portion 42 b, and three pieces of the outer wall portions 41 b, 41 c, 41 d is defined as a capacitor housing space S C .
- the thicknesses of the all partition wall portions 42 ( 42 a, 42 b ) of the case 4 are made thinner than those of the outer wall portions 41 .
- the remainder has the same structure, functions and effects as in the first embodiment.
- the present embodiment is an example that a shape of the case 4 is changed.
- the case 4 of the present embodiment includes two lateral partition wall portions 42 c.
- the interposing partition wall portion 42 a is formed so as to connect the two lateral partition wall portions 42 c.
- the bottom partition wall portion 42 b (refer to FIG. 3 ) is formed in the same manner as in the first embodiment in the present embodiment.
- a space surrounded by the interposing partition wall portion 42 a , the bottom partition wall portion 42 b, two lateral partition wall portions 42 c, and the supporting outer wall portions 41 d is defined as a capacitor housing space S C .
- the thicknesses of the all partition wall portions 42 ( 42 a, 42 b , 42 c ) of the case 4 are made thinner than those of the outer wall portions 41 .
- the remainder has the same structure, functions and effects as in the first embodiment.
- the present embodiment is an example that a shape of the case 4 is changed.
- the case 4 of the present embodiment includes two lateral partition wall portions 42 c.
- the interposing partition wall portion 42 a is formed so as to connect the two lateral partition wall portions 42 c.
- the case 4 of the present embodiment has an opposing partition wall portion 42 d disposed parallel to the interposing partition wall portion 42 a.
- the opposing partition wall portion 42 d is formed so as to connect the two lateral partition wall portions 42 c.
- the bottom partition wall portion 42 b (refer to FIG. 3 ) is formed in the same manner as in the first embodiment in the present embodiment.
- a space surrounded by the interposing partition wall portion 42 a , the bottom partition wall portion 42 b, two lateral partition wall portions 42 c, and the opposing partition wall portion 42 d is defined as a capacitor housing space S C .
- the thicknesses of the all partition wall portions 42 ( 42 a ⁇ 42 d ) of the case 4 are made thinner than those of the outer wall portions 41 .
- the remainder has the same structure, functions and effects as in the first embodiment.
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Abstract
An electric power converter includes a laminated body, a capacitor, a case, and a pressing member. The laminated body is formed by laminating semiconductor modules and cooling pipes. The pressing member presses the laminated body in a laminating direction of the laminated body. The case has outer wall portions that form an outer shell, and partition wall portions formed in the case and are connected to the outer wall portions. The capacitor has capacitor elements and a sealing member. The sealing member is filled in a capacitor housing space in a state where the capacitor elements are sealed. Pressing force of the pressing member is applied to an interposing partition wall portion interposing between the laminated body and the capacitor among the partition wall portions. A thickness of the interposing partition wall portion is made thinner than any other parts of the outer wall portions.
Description
- This application is based on and claims the benefit of priority from earlier Japanese Patent Application no. 2014-209963 filed Oct. 14, 2014, the description of which is incorporated herein by reference.
- The present disclosure relates to an electric power converter that has a semiconductor module with a built-in semiconductor element and a capacitor connected to the semiconductor module.
- As an electric power converter that performs power conversion between DC power and AC power, one that has a laminated body obtained by laminating a plurality of semiconductor modules with built-in semiconductor elements and a plurality of cooling pipes for cooling the semiconductor module, and that houses the laminated body in a metal casing has been known (refer to Japanese Patent Application Laid-Open Publication No. 2013-55840).
- In the abovementioned electric power converter, a pressing member such as a leaf spring is housed in the metal casing. The laminated body is pressurized in a laminating direction by the pressing member. Thereby, it is configured that while ensuring a contact pressure between the semiconductor modules and the cooling pipes, the laminated body is fixed in the metal casing. Moreover, a capacitor connected to the semiconductor modules is housed in the metal casing.
- The metal casing includes outer wall portions that form an outer shell, and partition wall portions formed in the case, which are connected to the outer wall portions. A space within the metal casing is partitioned into a capacitor housing space for housing the capacitor and a laminated body housing space for housing the laminated to body by the partition walls. The pressing force of the pressing member is applied to the partition walls.
- The capacitor includes a capacitor case made of resin, capacitor elements disposed in the capacitor case, and a sealing member for sealing the capacitor elements in the capacitor case. The capacitor is housed in the capacitor housing space. A gap is formed between the capacitor case and the metal casing (refer to
FIG. 10 ). - However, the above-mentioned electric power converter has a problem that cooling performance of the capacitor is not sufficiently high. That is, as described above, in the above-mentioned electric power converter, the capacitor elements are sealed in the capacitor case, and the gap is formed between the capacitor case and the metal casing. Thereby, the heat generated from the capacitor elements is transmitted to the metal casing via the sealing member, the capacitor case, and the gap. Therefore, a thermal resistance from the capacitor elements to the metal casing is large, and it is impossible to increase sufficiently the cooling performance of the capacitor.
- Further, since there is the gap between the partition wall and the capacitor in the electric power converter, it is necessary to receive the pressing force of the pressing member on the partition wall. Therefore, in order not to cause it to deform due to the pressing force, it is necessary to form the partition wall thickly. Thus, there is a problem that it is difficult to lighten the electric power converter. Further, when the partition wall is thick, it becomes difficult to reduce the size of the metal casing, which makes it difficult to downsize the electric power converter.
- An embodiment provides an electric power converter that can be downsized and lightened, while capable of improving cooling efficiency of a capacitor.
- In an electric power converter according to a first aspect includes a laminated body formed by laminating a plurality of semiconductor modules having built-in semiconductor elements and a plurality of cooling pipes for cooling the semiconductor modules alternately, a capacitor connected to the plurality of semiconductor modules, a pressing member that presses the laminated body in a laminating direction of the laminated body, and a metal case that houses the laminated body, the capacitor, and the pressing member.
- The case has outer wall portions that form an outer shell, and partition wall portions formed in the case that are connected to the outer wall portions, a space within the case being partitioned by the partition wall portions into a capacitor housing space for housing the capacitor and a laminated body housing space for housing the laminated body, the capacitor including capacitor elements housed in the capacitor housing space, and a sealing member that is filled in the capacitor housing space for sealing the capacitor elements, the capacitor being disposed at a position adjacent to the laminated body in the laminating direction, pressing force of the pressing member being applied to an interposing partition wall portion interposing between the laminated body and the capacitor among the partition well portions in its thickness direction, and a thickness of the interposing partition wall to portion is made thinner than any other parts of the outer wall portions.
- In the above-mentioned electric power converter, the capacitor housing space is filled with the sealing member. Thus, the sealing member can be brought into contact with the partition wall portions and the outer wall portions of the case. Therefore, the heat generated from the capacitor can be transmitted immediately to the metal case via the sealing member. As a result, it is possible to reduce the thermal resistance from the capacitor elements to the case, thus it is possible to enhance the cooling efficiency of the capacitor.
- Further, in the above-mentioned electric power converter, the interposing partition wall portion interposed between the capacitor and the laminated body among the partition wall portions is formed thinner than any other parts of the outer wall portions. Therefore, it is possible to downsize and lighten the case. In the above electric power converter, since the capacitor housing space is filled with the sealing member, it is possible to bring the sealing member to contact with the interposing partition wall portion. Thus, there is no gap present between the sealing member and the interposing partition wall portion, and even when the pressing force of the pressing member is applied to the interposing partition wall portion, the pressing force can be received by the sealing member. Therefore, it is possible to make the interposing partition wall portion thin, and it is possible to achieve downsizing and lightening of the case.
- As described above, according to the present disclosure, it is possible to provide the electric power converter that can further be lightened and downsized, and capable of improving the cooling efficiency of the capacitor.
- In the accompanying drawings:
-
FIG. 1 shows a sectional view of an electric power converter, and is a sectional view taken along the line I-I ofFIG. 2 in a first embodiment; -
FIG. 2 shows a sectional view taken along the line II-II ofFIG. 1 ; -
FIG. 3 shows a sectional view taken along the line ofFIG. 1 ; -
FIG. 4 shows a sectional view taken along the line IV-IV ofFIG. 2 ; -
FIG. 5 shows an exploded perspective view of a case main body in the first embodiment; -
FIG. 6 shows a circuit diagram of the electric power converter in the first embodiment; -
FIG. 7 shows a sectional view of an electric power converter in a second embodiment; -
FIG. 8 shows a sectional view of an electric power converter in a third embodiment; -
FIG. 9 shows a sectional view of an electric power converter in a fourth embodiment; and -
FIG. 10 shows a sectional view of an electric power converter in a comparative example. - An above-mentioned electric power converter can be defined as an on-vehicle electric power converter for mounting on a vehicle such as an electric vehicle or a hybrid vehicle.
- An embodiment according to an electric power converter will be described with reference to
FIGS. 1 to 6 . As shown inFIG. 1 , anelectric power converter 1 of the present embodiment includes a laminatedbody 10, acapacitor 3, ametal case 4, and apressing member 5. The laminatedbody 10 is formed by laminating a plurality ofsemiconductor modules 2 having built-in semiconductor elements 20 (refer toFIG. 6 ) and a plurality ofcooling pipes 11 for cooling thesemiconductor modules 2 alternately. Thecapacitor 3 is connected to thesemiconductor modules 2. - The pressing
member 5 presses the laminatedbody 10 in a laminating direction of the laminated body 10 (X-direction). Thereby, while ensuring a contact pressure between thesemiconductor modules 2 and thecooling pipes 11, the laminatedbody 10 is fixed in thecase 4. The above-mentioned laminatedbody 10, thecapacitor 3, so and thepressing member 5 are housed in thecase 4. - The
case 4 hasouter wall portions 41 that form an outer shell, andpartition wall portions 42 formed in thecase 4 and are connected to theouter wall portions 41. A space within thecase 4 is partitioned by thepartition wall portions 42 into a capacitor housing space SC for housing thecapacitor 3 and a laminated body housing space SL for housing the laminated body. - The
capacitor 3 includescapacitor elements 30 housed in the capacitor housing space SC, and asealing member 31 that is filled in the capacitor housing space SC for sealing thecapacitor elements 30. - The
capacitor 3 is disposed at a position adjacent to the laminatedbody 10 in the X direction. Pressing force of thepressing member 5 is applied to an interposingpartition wall portion 42 a interposing between thelaminated body 10 and thecapacitor 3 among thepartition wall portions 42 in its thickness direction (X direction). The thickness of the interposingpartition wall portion 42 a is made thinner than any other parts of theouter wall portions 41. - The
electric power converter 1 of the present embodiment is an on-vehicle electric power converter for mounting on a vehicle such as an electric vehicle or a hybrid vehicle. - As shown in
FIG. 6 , aninverter circuit 200 is constituted by a plurality ofsemiconductor modules 2 in the present embodiment. DC power supplied from aDC power supply 81 is converted into AC power by turning on and off the semiconductor elements 20 (IGBT elements) in thesemiconductor modules 2. Then, a three-phase AC motor 82 is driven by using the obtained AC power, thereby drives the vehicle. - The
capacitor 3 is connected to thesemiconductor modules 2. DC voltage applied to the semiconductor modifies 2 is smoothened by using thecapacitor 3. - As shown in
FIG. 3 andFIG. 4 , theelectric power converter 1 of the present embodiment includes the interposingpartition wall portion 42 a, a bottompartition wall portion 42 b, and a lateralpartition wall portion 42 c as thepartition wall portions 42. The bottompartition wall portion 42 b is orthogonal to the interposingpartition wall portion 42 a. The bottompartition wall portion 42 b is disposed on a side opposite to anopening 12 of the capacitor housing space SC. - Further, the lateral
partition wall portion 42 c is orthogonal to both the interposingpartition wall portion 42 a and the bottompartition wall portion 42 b. In the present embodiment, a space surrounded by the interposingpartition wall portion 42 a, the bottompartition wall portion 42 b, the lateralpartition wall portion 42 c, and theouter wall portions 41 is defined as the capacitor housing space SC. - The thicknesses of the interposing
partition wall portion 42 a, the bottompartition wall portion 42 b, and the lateralpartition wall portion 42 c are made thinner than any other parts of theouter wall portions 41. - As described above, in the present embodiment, the space in the
case 4 is divided into the capacitor housing space SC and the laminated body housing space SL by the partition wall portions 42 (42 a˜42 c). In addition to thelaminated body 10, a control circuit board 6 and aterminal block 16 are housed in the laminated body housing space SL. - As shown in
FIG. 3 andFIG. 4 , thecapacitor 3 includes thecapacitor elements 30 housed in the capacitor housing space SC, the sealingmember 31 for sealing thecapacitor elements 30 in the capacitor housing space SC, and 32, 33 connected to theelectrode plates capacitor elements 30. Thecapacitor elements 30 are so-called film capacitors. - The sealing
member 31 is made of a thermosetting resin such as epoxy resin. The sealingmember 31 fills gaps between thecapacitor elements 30, the 32, 33, and theelectrode plates case 4 in the capacitor housing space SC. Thereby, thecapacitor elements 30 and the 32, 33 are sealed. Theelectrode plates 32, 33 are connected to electrodeelectrode plates 350, 351 of thesurfaces capacitor elements 30. Parts of the 32, 33 protrude from the sealingelectrode plates member 31. The 32, 33 are integrated with DC bus bars 34 p, 34 n which will be described later.electrode plates - When manufacturing the
capacitor 3, thecapacitor elements 30 are housed into the capacitor housing space SC, then uncured sealingmember 31 is injected. Then, heat is applied to cure the sealingmember 31. Thereby, thecapacitor 3 is manufactured. - Meanwhile, as shown in
FIG. 4 , the pressingmember 5 is disposed in the X direction between thelaminated body 10 and the interposingpartition wall portion 42 a in the present embodiment. Thepressing member 5 of the present embodiment is a leaf spring. Thelaminated body 10 is pressed toward theouter wall portion 41 a of thecase 4 by the pressingmember 5. The pressing force F of thepressing member 5 is applied to the interposingpartition wall portion 42 a and thecapacitor 3. - Two cooling
pipes 11 adjacent in the X direction are connected by connectingpipes 17 at both end portions thereof in a longitudinal direction of the cooling pipe 11 (Y-direction). Furthermore, aninlet pipe 13 for introducing a refrigerant 15 and anoutlet pipe 14 for discharging the refrigerant 15 are connected to anend cooling pipe 11 a positioned at one end in the X direction among the plurality of coolingpipes 11. When introducing the refrigerant 15 from theinlet pipe 13, the refrigerant 15 flows all of the coolingpipes 11 through the connectingpipes 17, and discharged from theoutlet pipe 14. Thereby, thesemiconductor modules 2 are cooled. - As shown in
FIG. 2 , therespective semiconductor module 2 has amain body 21 with a built-insemiconductor element 20, andpower terminals 22 andcontrol terminals 23 protruding from themain body 21. As thepower terminals 22, there are 22 p, 22 n to which DC voltage is applied, and there areDC terminals AC terminals 22 c connected to the three-phase AC motor 82 (refer toFIG. 6 ). The 22 p, 22 n are connected to theDC terminals capacitor 3 via the DC bus bars 34 p, 34 n. - The
control terminals 23 are connected to the control circuit board 6. An on-off operation of the semiconductor element 20 (refer toFIG. 6 ) is controlled by the Control circuit board 6. Thereby, the DC power supplied from theDC power supply 81 is converted into the AC power, - As shown in
FIG. 1 , theelectric power converter 1 includesinput terminals 71 for being connected to the DC power supply 81 (refer toFIG. 6 ), andoutput terminals 72 for being connected to the three-phase AC motor 82. Theinput terminals 71 are connected to thecapacitor 3. Further, AC bus bars 720 are connected to theAC terminal 22 c of thesemiconductor modules 2. Ends of the AC bus bars 720 are theaforementioned output terminals 72. - As shown in
FIG. 1 andFIG. 4 , theterminal block 16 for mounting theinput terminals 71 andoutput terminals 72 are housed in thecase 4. Theterminal block 16 is made of resin, Theterminal block 16 is disposed at a position adjacent to thecapacitor 3 in the Y direction, - As shown in
FIG. 1 andFIG. 5 , aconnector insertion hole 49 is formed in theouter wall portion 41 of thecase 4. Theconnector insertion hole 49 penetrates in the Y direction. Aconnector 18 is inserted into theconnector insertion hole 49.Input connector terminals 181 of theconnector 18 are connected to theinput terminals 71 of theelectric power converter 1. In addition,output connector terminals 182 of theconnector 18 are connected to theoutput terminals 72. Theelectric power converter 1 is electrically connected to theDC power supply 81 and the three-phase AC motor 82 via theconnector 18. - As shown in
FIG. 2 andFIG. 3 , thecase 4 of the present embodiment includes a casemain body 401 for housing thelaminated body 10 and thecapacitor 3, and covers 402, 403 attached to the casemain body 401. The 402, 403 also constitute thecovers outer wall portions 41 of thecase 4. - As shown in
FIG. 5 , a plurality of reinforcingwall portions 43 are formed to the casemain body 401 in addition to thepartition wall portions 42. A rigidity of thecase 4 has been increased by the reinforcingwall portions 43. Thus, thecase 4 is configured not to be deformed by the pressing force F of the pressing member 5 (seeFIG. 4 ). - Further, among the
outer wall portions 41 of thecase 4, theouter wall portion 41 a to which theinlet pipe 13 and so theoutlet pipe 14 are disposed has a double structure in which a firstouter wall portion 411 and a secondouter wall portion 412 are overlapped with each other. The firstouter wall portion 411 is positioned on an inside of thecase 4, while the secondouter wall portion 412 is positioned on an outside of thecase 4. A throughhole 44 penetrating in the X direction is formed in the firstouter wall portion 411. The throughhole 44 is closed by the secondouter wall portion 412. The secondouter wall portions 412 is fixed to the firstouter wall portion 411 bybolts 48. - As shown in
FIG. 2 , a distance L in the Y direction between the two reinforcing 43 a, 43 b adjacent in the Y direction is shorter than the length of the coolingwall portions pipe 11 in the Y-direction. Therefore, when manufacturing theelectric power converter 1, it is not possible to put the coolingpipes 11 in thecase 4 through a gap G formed between the two reinforcing 43 a, 43 b. Therefore, the coolingwall portions pipes 11 are configured to be placed in thecase 4 from the throughhole 44 in the present embodiment. - Functions and effects of the present embodiment will be described. As shown in
FIG. 1 andFIG. 3 , the capacitor housing space SC is filled with the sealingmember 31 in the present embodiment. Thus, the sealingmember 31 can be brought into contact with thepartition wall portions 42 and theouter wall portions 41 of thecase 4. Therefore, heat generated from the capacitor elements 30 s can be transmitted immediately to themetal case 4 via the sealingmember 31. As a result, it is possible to reduce the thermal resistance from thecapacitor elements 30 to thecase 4, and thus it is possible to enhance the cooling efficiency of thecapacitor 3. - Further, among the
partition wall portions 42, the interposingpartition wall portion 42 a interposing between thecapacitor 3 and thelaminated body 10 is made thinner than any other parts of theouter wall portions 41 in the present embodiment. Therefore, it is possible to downsize thecase 4, and it can be lightened. Since the capacitor housing space SC is filled with the sealingmember 31 in the present embodiment, it is possible to bring the sealingmember 31 to contact with the interposingpartition wall portion 42 a. Thus, there is no gap present between the sealingmember 31 and the interposingpartition wall portion 42 a, and even when the pressing force F of thepressing member 5 is applied to the interposingpartition wall portion 42 a, the pressing force F can be received by the sealingmember 31. Therefore, it is possible to make the interposingpartition wall portion 42 a thin, and it is possible to achieve downsizing and lightening of thecase 4. - As shown in
FIG. 10 , assuming that acapacitor 93 is constituted by sealingcapacitor elements 930 in acapacitor case 99, it is necessary to form a capacitor housing space SC slightly larger in order to house thecapacitor 93 easily. Thereby, a gap g is formed between thecapacitor 93 and acase 94 as a result. Therefore, heat generated from thecapacitor elements 930 will be transmitted to thecase 94 via a sealingmember 931, thecapacitor case 99, and the gap g. As a result, the thermal resistance from thecapacitor elements 930 to thecase 94 becomes large, and it becomes difficult to sufficiently enhance the cooling efficiency of thecapacitor 93. - In addition, when the gap g is formed, the pressing force F of a pressing
member 95 is needed to be received by an interposingpartition wall 942 a. Therefore, in order not to be deformed by the pressing force F, the interposingpartition wall portion 942 a is needed to be formed thicker. Thus, thecase 94 becomes large, and it tends to become heavy. - In contrast, as shown in
FIG. 3 , since the sealingmember 31 comes into contact with the partition wellportions 42 and the like of thecase 4 by filling the capacitor housing space SC with the sealingmember 31 as in the present embodiment, the heat generated from thecapacitor elements 30 is transmitted immediately to thecase 4 via the sealingmember 31. Therefore, it is possible to enhance the cooling efficiency of thecapacitor 3. Further, since no gap is formed between the sealingmember 31 and the interposingpartition wall portion 42 a, the pressing force F of thepressing member 5 applied to the interposingpartition wall portion 42 a can be received by the sealingmember 31. Therefore, It is possible, to make the interposingpartition wall portion 42 a thinner, thus thecase 4 can be downsized and lightened. - Furthermore, as shown in
FIG. 1 andFIG. 3 , in addition to the interposingpartition wall portion 42 a, the bottompartition wall portion 42 b and the lateralpartition wall portion 42 c are also made thinner than any other parts of theouter wall portions 41 in the present embodiment. Therefore, thecase 4 can be more lightened, and can be more downsized. As a result, theelectric power converter 1 can be lightened and downsized. - In addition, as shown in
FIG. 1 andFIG. 3 , a supportingouter wall portion 41 d disposed in a position farther from thelaminated body 10 than thecapacitor 3 is in the X direction is provided as theouter wall portion 41 in the present embodiment. The sealingmember 31, of thecapacitor 3 is in contact with the supportingouter wall portion 41 d. Therefore, the pressing force F of thepressing member 5 applied to the sealingmember 31 can be received by the supportingouter wall portions 41 d which is thicker than thepartition wall portions 42. - As described above, according to the present disclosure, it is possible to provide the electric power converter what while further capable of being lightened and downsized, improves the cooling efficiency of the capacitor.
- Incidentally, as shown in
FIG. 4 , although the pressing member S is disposed between thelaminated body 10 and the interposingpartition wall portion 42 a in the present embodiment, the present disclosure is not limited thereto. That is, the pressingmember 5 can also be disposed between thelaminated body 10 and theouter wall portion 41 a. In this case, the pressingmember 5 is to press thelaminated body 10 toward the interposingpartition wall portion 42 a. - In the following embodiments, among the reference numerals used in the drawings, ones having the same reference numerals as used in the first embodiment represent the same constituent elements as the first embodiment unless otherwise indicated.
- The present embodiment is an example that a shape of the
case 4 is changed. As shown inFIG. 7 , the interposingpartition wall portion 42 a is formed so as to connect two pieces of the 41 b, 41 c, in the present embodiment. The lateralouter wall portions partition wall portion 42 c (refer toFIG. 1 ) is not formed in the present embodiment. - Further, the bottom
partition wall portion 42 b (refer toFIG. 3 ) is formed in the same manner as in the first embodiment in the present embodiment. A space surrounded by the interposingpartition wall portion 42 a, the bottompartition wall portion 42 b, and three pieces of the 41 b, 41 c, 41 d is defined as a capacitor housing space SC. The thicknesses of the all partition wall portions 42 (42 a, 42 b) of theouter wall portions case 4 are made thinner than those of theouter wall portions 41. The remainder has the same structure, functions and effects as in the first embodiment. - The present embodiment is an example that a shape of the
case 4 is changed. As shown inFIG. 8 , thecase 4 of the present embodiment includes two lateralpartition wall portions 42 c. The interposingpartition wall portion 42 a is formed so as to connect the two lateralpartition wall portions 42 c. - Further, the bottom
partition wall portion 42 b (refer toFIG. 3 ) is formed in the same manner as in the first embodiment in the present embodiment. A space surrounded by the interposingpartition wall portion 42 a, the bottompartition wall portion 42 b, two lateralpartition wall portions 42 c, and the supportingouter wall portions 41 d is defined as a capacitor housing space SC. The thicknesses of the all partition wall portions 42 (42 a, 42 b, 42 c) of thecase 4 are made thinner than those of theouter wall portions 41. The remainder has the same structure, functions and effects as in the first embodiment. - The present embodiment is an example that a shape of the
case 4 is changed. As shown inFIG. 9 , thecase 4 of the present embodiment includes two lateralpartition wall portions 42 c. The interposingpartition wall portion 42 a is formed so as to connect the two lateralpartition wall portions 42 c. Further, thecase 4 of the present embodiment has an opposingpartition wall portion 42 d disposed parallel to the interposingpartition wall portion 42 a. The opposingpartition wall portion 42 d is formed so as to connect the two lateralpartition wall portions 42 c. - Further, the bottom
partition wall portion 42 b (refer toFIG. 3 ) is formed in the same manner as in the first embodiment in the present embodiment. A space surrounded by the interposingpartition wall portion 42 a, the bottompartition wall portion 42 b, two lateralpartition wall portions 42 c, and the opposingpartition wall portion 42 d is defined as a capacitor housing space SC. The thicknesses of the all partition wall portions 42 (42 a˜42 d) of thecase 4 are made thinner than those of theouter wall portions 41. The remainder has the same structure, functions and effects as in the first embodiment.
Claims (4)
1. An electric power converter comprising:
a laminated body formed by laminating a plurality of semiconductor modules having built-in semiconductor elements and a plurality of cooling pipes for cooling the semiconductor modules alternately;
a capacitor connected to the plurality of semiconductor modules;
a pressing member that presses the laminated body in a laminating direction of the laminated body; and
a metal case that houses the laminated body, the capacitor, and the pressing member; wherein,
the case has outer wall portions that form an outer shell, and partition wall portions formed in the case and are connected to the outer wall portions;
a space within the case Is partitioned by the partition wall portions into a capacitor housing space for housing the capacitor and a laminated body housing space for housing the laminated body;
the capacitor includes capacitor elements housed in the capacitor housing space, and a sealing member that is filled in the capacitor housing space for sealing the capacitor elements;
the capacitor is disposed at a position adjacent to the laminated body in the laminating direction;
pressing force of the pressing member is applied to an interposing partition wall portion interposing between the laminated body and the capacitor among the partition wall portions in its thickness direction; and
a thickness of the interposing partition wall portion is made thinner than any other parts of the outer wall portions.
2. The electric power converter according to claim 1 , further comprising,
a bottom partition wall portion that is orthogonal to the interposing partition wall portion and is disposed on a side opposite to an opening of the capacitor housing space;
a lateral partition wall portion that is orthogonal to both the interposing partition wall portion and the bottom partition wall portion;
the bottom partition wall portion and the lateral partition wall portion are provided as the partition wall portions; and
the thicknesses of the bottom partition wall portion and the lateral partition wall portion are made thinner than any other parts of the outer wall portions.
3. The electric power converter according to claim 1 , wherein,
a supporting outer wall portion disposed in a position farther from the laminated body than the capacitor is in the laminating direction is provided as the outer wall portion; and
the sealing member is in contact with the supporting outer wall portion.
4. The electric power converter according to claim 2 , wherein,
a supporting outer wall portion disposed in a position farther from the laminated body than the capacitor is in the laminating direction is provided as the outer wall portion; and
the sealing member is In contact with the supporting outer wall portion.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2014-209963 | 2014-10-14 | ||
| JP2014209963A JP6394262B2 (en) | 2014-10-14 | 2014-10-14 | Power converter |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| US20160106011A1 true US20160106011A1 (en) | 2016-04-14 |
| US10070565B2 US10070565B2 (en) | 2018-09-04 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US14/883,034 Active US10070565B2 (en) | 2014-10-14 | 2015-10-14 | Electric power converter |
Country Status (2)
| Country | Link |
|---|---|
| US (1) | US10070565B2 (en) |
| JP (1) | JP6394262B2 (en) |
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| US20160192539A1 (en) * | 2014-12-24 | 2016-06-30 | Toyota Jidosha Kabushiki Kaisha | Stack unit |
| US20180098457A1 (en) * | 2016-09-30 | 2018-04-05 | Denso Corporation | Power converter |
| US20200028443A1 (en) * | 2018-07-19 | 2020-01-23 | Denso Corporation | Power converter |
| CN114208014A (en) * | 2019-09-20 | 2022-03-18 | 日立安斯泰莫株式会社 | Power conversion device and motor-integrated power conversion device |
| US11424073B2 (en) * | 2017-06-21 | 2022-08-23 | Bayerische Motoren Werke Aktiengesellschaft | DC link capacitor |
| EP4138531A1 (en) * | 2021-08-18 | 2023-02-22 | Hyundai Motor Company | Inverter apparatus of mobility |
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| US12302540B2 (en) * | 2023-01-26 | 2025-05-13 | Dana Tm4 Inc. | Inverter with capacitor discharge and cooling system |
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| JP6596398B2 (en) * | 2016-08-29 | 2019-10-23 | 本田技研工業株式会社 | Power converter |
| JP6919348B2 (en) * | 2017-06-07 | 2021-08-18 | 株式会社デンソー | Power converter |
| JP6921282B1 (en) * | 2020-07-17 | 2021-08-18 | 三菱電機株式会社 | Power converter |
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Also Published As
| Publication number | Publication date |
|---|---|
| US10070565B2 (en) | 2018-09-04 |
| JP6394262B2 (en) | 2018-09-26 |
| JP2016082646A (en) | 2016-05-16 |
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